Shelf-stable one-part room temperature vulcanizing fluorosilicone compositions

ABSTRACT

A method for continuously producing a room temperature vulcanizable composition is disclosed. A base mixture of a silanol stopped fluorosilicone polymer, a silica filler and iron oxide are processed in an extruder at an elevated temperature between about 50° and 200° C. Thereafter, a tin based catalyst, an acetoxy cross-linking agent and an optional adhesion promoter are added to the extruder near the exit port. The resulting material has improved storage stability.

This is a divisional of application Ser. No. 07/990,214 filed on Dec. 14, 1992, now U.S. Pat. No. 5,354,833.

BACKGROUND OF THE INVENTION

The present invention relates to one-part room temperature vulcanizing (RTV) rubber sealant compositions. More particularly, the invention relates to RTV fluorosilicone rubber sealant compositions being continuously processed in an extruder at high temperatures and having improved storage stability.

RTV fluorosilicone rubber sealant compositions are known in the art. Such compositions are known for their ability to resist change at elevated temperatures and exposure to adverse conditions over extended periods of time. In general, materials are needed which have the outstanding properties such as good tensile strength and also retain such properties after prolonged storage prior to cure.

Efforts have been made in the past to produce RTV silicone elastomer compositions having increased strength and adhesion.

Exemplary RTV elastomers are disclosed in U.S. Pat. No. 4,514,529 to Beers et al. and Lucas et al., U.S. Pat. No. 4,523,353.

Although one-part RTV compositions having reasonably good tensile physical properties are known in the art, it is desirable to produce on a continuous basis, as opposed to batch process, RTV compositions having good physical properties and cure characteristics after prolonged storage.

SUMMARY OF THE INVENTION

The present invention is based upon the discovery that a base polymer comprising a blend of a silanol stopped fluorosilicone polymer, a treated silica filler, and iron oxide may be continuously processed in an extruder at an elevated temperature followed by the addition of an acetoxy crosslinker, a tin based catalyst and an optional adhesion promoter further down the extruder to produce an RTV sealant having good room temperature adhesion and tensile strength and retainable cure properties after prolonged storage.

In a particular embodiment, the invention comprises (A) a base composition including (A1) 100 parts by weight of a silanol stopped fluorosilicone polymer such as poly(methyltrifluoropropyl) siloxane having a viscosity ranging from about 600 to about 300,000 cps at 25° C.; (A2) from about 3 to about 25 parts by weight based upon (A1) of a treated silica filler; (A3) up to about 200 parts by weight based upon (A1) of finely divided Fe₂ O₃ having a particle size ranging from about 0.05 to about 5 microns. In addition, the RTV composition also includes (B) a catalyst solution comprising (B1) up to about 0.5 parts by weight based upon (A) of a tin based catalyst; (B2) from about 2 to about 15 parts by weight based upon (A) of an acetoxy cross-linking agent comprising (a) a methyltriacetoxy silane or (b) ethyltriacetoxysilane or mixtures of (a) and (b); and (B3) from about 0.1 to about 4 parts by weight based upon (A) of diacetoxydibutoxysilane adhesion promoter. The base composition is continuously processable at an elevated temperature ranging from about 50 to about 200° C. and the catalyst solution (B) is added at near room temperature after processing (A).

The RTV compositions of the invention cure well and importantly retain curable properties after prolonged storage in the uncured state.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to an RTV curable fluorosilicone sealant composition which may be produced on a continuous basis and which has good cured properties after prolonged storage in the uncured state. The composition comprises (A) a base composition formed of (A1) a fluorosilicone polymer; (A2) a silica filler; and (A3) Fe₂ O₃. The base composition (A) is combined with (B) a catalyst solution including (B1) a tin based catalyst; (B2) an acetoxy cross-linking agent; and (B3) an optional adhesion promoter.

In accordance with the invention, (A1) is a silanol terminated fluorosilicone having a viscosity ranging from about 600 to about 300,000, preferably from about 2,000 to 200,000 and more preferably from about 3,000 to about 150,000 cps at 25° C. In the examples below, (A1) is a silanol stopped poly(methyltrifluoropropyl) siloxane having the formula:

    HO(RR.sup.1 SiO).sub.x OH

where R is independently selected from monovalent hydrocarbon radicals, free of aliphatic unsaturation containing from 1 to about 8 carbon atoms, R¹ is independently selected from fluorinated monovalent hydrocarbon radicals free of aliphatic unsaturation containing from 1 to about 8 carbon atoms and x varies so that (A1) has a viscosity ranging from about 600 to about 300,000 cps at 25° C. In the examples below, x is selected so that (A1) has a viscosity of about 15,000 cps at 25° C.

(A2) comprises from about 3 to about 25, preferably from about 3 to about 20 and more preferably from about 5 to about 15 parts by weight based upon (A1) of a reinforcing filler such as fumed silica (SiO₂). The filler preferably has a surface area of between 100 and 300 m² /gm, more preferably, the surface area is about 200 m² /gm in the untreated state. The filler may be treated with various agents so as to prevent the composition from structuring, for example, cyclopolysiloxanes as disclosed in U.S. Pat. No. 2,938,009 to Lucas and silazanes as disclosed in U.S. Pat. No. 3,635,743 to Smith, or both. The cyclopolysiloxanes may be, for example, octamethylcyclotetrasiloxane, present in an amount ranging from about 15 to about 20 weight percent of the filler. In the examples below, (A2) is a trimethylsilyl treated fumed silica having a surface area in the untreated state of about 200 m² /gm.

(A3) is a finely divided Fe₂ O₃ iron oxide powder having an average particle size ranging from about 0.05 to about 5 microns. (A3) is present in an amount up to 200 parts, preferably up to about 60 parts and more preferably 30 parts by weight based upon 100 parts of (A1).

In the examples below, (A3) is a commercially available product sold by Pfizer under the trade designation R2200 having an average particle size of about 0.25 microns.

(B1) is a tin based catalyst which may be present in an amount up to about 0.50 parts by weight based upon 100 parts of the base composition (A).

Preferably, the catalyst is present in an amount from about 0.01 to about 0.4 parts by weight based upon (A), and more preferably (B1) is present in an amount ranging from about 0.05 to about 0.30 parts based upon (A). In the examples below, (B1)(a) is dibutyltindilaurate and (B1)(b) is dibutyltindiacetate.

(B2) is an acetoxy silane cross-linking agent. Preferably, (B2) comprises (a) methyltriacetoxy silane or (b) ethyltriacetoxysilane or mixtures of (a) and (b). The cross-linking agent is present in an amount from about 2 to about 15 parts by weight based upon 100 parts of the base composition (A), preferably from 2 to about 10 parts by weight based upon (A), and more preferably from about 3 to about 7 parts by weight based upon (A).

(B3) is an optional adhesion promoter which may be present in an amount from about 0.1 to about 4 parts by weight based upon 100 parts of the base composition (A), preferably from about 0.2 to about 2 parts by weight based upon (A) and more preferably ranging from about 0.3 to about 1.5 parts by weight based upon (A). (B3) may, for example, be diacetoxydibutoxysilane.

The following examples demonstrate the effect of the present invention. Examples 1 and 2 set forth the preparation and testing of sealants in which the base polymer (A) is prepared by combining Components (A1), (A2) and (A3) in a first supply port of an extruder. In Examples 1 and 3, (A1), (A2) and (A3) are continuously processed at a low temperature. In Examples 2 and 4, (A1), (A2) and (A3) are continuously processed at a high temperature. Components (B1), (B2) and (B3) are added at a supply port between the first supply port and the extruder exit port.

EXAMPLE 1

An extruder was set up to combine the following ingredients in the following proportions:

(A) base composition:

(A1) 100 parts--silanol stopped fluorosilicone polymer (approximately 150,000 cps at 25° C.) poly(methyltrifluoropropyl) siloxane;

(A2) 9 parts by weight based upon (A1)--trimethyl silyl treated fumed silica, 200 m² /gm in the untreated state;

(A3) 30 parts by weight based upon (A1)--Fe₂ O₃.

The above materials were added to the extruder to constitute the base composition and were continuously processed at 50° C. for about 1 min. Thereafter, 5.79 parts by weight based upon the sum of (A1), (A2) and (A3) of a catalyst solution (B) was added to the end of the extruder:

Catalyst solution:

(B1)(b) dibutyltindiacetate--1.2 parts;

(B2)(a) methyltriacetoxy silane--80 parts;

(B3) diacetoxydibutoxy silane--20 parts;

Shortly after manufacture, the material was tested for physical properties after curing 7 days at 75° C. at 50% relative humidity. The results are listed on Table 1-A.

                  TABLE 1A     ______________________________________                     Initial     ______________________________________     Shore A            32     Tensile Strength (psi)                       526     Elongation %      312     Mod. at 50% ext. (psi)                        64     ______________________________________

Samples of the uncured sealant were stored at room temperature for one year and tested in a similar fashion. The results are listed in Table 1B.

                  TABLE 1B     ______________________________________                     Initial     ______________________________________     Shore A            10     Tensile Strength (psi)                       124     Elongation %      365     Mod at 50% ext. (psi)                        23     ______________________________________

After storage, the sealant cured to an elastomer which was 22 Shore A points lower and retained only about 24% of its initial tensile strength.

EXAMPLE 2

The materials were combined as set forth in Example 1 except that processing temperature of the base polymer (A) was maintained at 100° C. Initial properties and resulting properties after one year are set forth in Tables 2A and 2B, respectively.

                  TABLE 2A     ______________________________________                     Initial     ______________________________________     Shore A            34     Tensile Strength (psi)                       533     Elongation %      333     Mod at 50% ext. (psi)                        68     ______________________________________

                  TABLE 2B     ______________________________________                     Initial     ______________________________________     Shore A            22     Tensile Strength (psi)                       428     Elongation %      438     Mod at 50% ext. (psi)                        40     ______________________________________

After one year in storage, the material cured to an elastomer which was only 12 Shore A points lower and which retained approximately 80% of its initial tensile strength, demonstrating improved shelf life at elevated processing temperatures.

EXAMPLE 3

An extruder was set up to combine the following ingredients in the following proportions:

    ______________________________________             (A1) 100 parts             (A2)  9 parts             (A3)  30 parts     ______________________________________

The above materials were added to the first section of the extruder and processed at 50° C. to constitute the base portion of the RTV sealant.

The catalyst solution (B) (5.79 parts per 100 5 parts of base (A)) was added to the later section of the extruder as described in Example 1.

    ______________________________________     Catalyst solution (B):     ______________________________________     (B1)(a) dibutyltindilaurate                             0.6   parts     (B2)(a) methyltriacetoxysilane                             80    parts     (B3) diacetoxydibutoxysilane                             30    parts     ______________________________________

The sealant was tested as set forth in Example 1 for initial properties and properties after one year storage in the uncured state. The initial properties are set forth in Table 3A and the properties after storage in the uncured state after one year are set forth in Table 3B.

                  TABLE 3A     ______________________________________                     Initial     ______________________________________     Shore A            32     Tensile Strength (psi)                       583     Elongation %      332     Mod at 50% ext. (psi)                        66     ______________________________________

                  TABLE 3B     ______________________________________                     Initial     ______________________________________     Shore A            19     Tensile Strength (psi)                       360     Elongation %      431     Mod at 50% ext. (psi)                        32     ______________________________________

After storage, the sealant cured to an elastomer which was 13 Shore A points lower and retained only 62% of the initial tensile strength.

EXAMPLE 4

The materials were combined as in Example 3 except that the basic polymer (A) was processed at 100° C. Initial properties and properties after one year are set forth below in Tables 4A and 4B, respectively.

                  TABLE 4A     ______________________________________                     Initial     ______________________________________     Shore A            33     Tensile Strength (psi)                       514     Elongation %      320     Mod at 50% ext. (psi)                        71     ______________________________________

                  TABLE 4B     ______________________________________                     Initial     ______________________________________     Shore A            27     Tensile Strength (psi)                       583     Elongation %      450     Mod at 50% ext. (psi)                        50     ______________________________________

The examples demonstrate that continuously produced fluorosilicone RTV sealants, when processed at elevated temperatures, exhibit improved storage stability.

While there has been described what at present are considered to be the preferred embodiments of the present invention, it will be readily apparent to those skilled in the art that various changes may be made therein without departing from the invention and it is intended in the appended claims to cover such changes and modifications as fall within the true spirit and scope of the invention. 

WHAT IS CLAIMED:
 1. A method for continuously producing a shelf stable room-temperature vulcanizable composition from an extruder having a first supply port, an exit port, and a second supply port located along said extruder between said first supply port and said exit port, said method comprising the steps of:(1) supplying a base composition (A) to said extruder at said first supply port and maintaining the temperature of the base composition between 100° and 200° C., said base composition (A) comprising: (A1) 100 parts by weight of a silanol terminated fluorosilicone having the formula HO(RR¹ SiO)_(x) OH, wherein each R is a monovalent hydrocarbon radical free of aliphatic unsaturation containing from 1 to about 8 carbon atoms, each R¹ is a fluorinated monovalent hydrocarbon free of aliphatic unsaturation having from 1 to about 8 carbon atoms and x varies so that (A1) has a viscosity of about 600 to about 300,000 cps at 25° C.; (A2) from about 3 to about 25 parts by weight based upon (A1) of a silica filler having a surface area of about 100 to 300 m² /gm in an untreated state, (A3) up to about 200 parts by weight based upon (A1) of finely divided Fe₂ O₃ having an average particle size ranging from about 0.05 to about 5 microns; (2) adding a catalyst solution (B) to said extruder at said second supply port, said catalyst solution (B) comprising: (B1) up to about 0.5 parts by weight based upon 100 parts of the base composition (A) of a tin based catalyst; and (B2) from about 2 to about 15 parts by weight based upon 100 parts of the sum of (A1), (A2) and (A3) of at least one acetoxy cross-linking agent.
 2. The method as defined in claim 1, wherein (B) further comprises:(B3) up to about 4 parts by weight based upon 100 parts of the sum of (A1), (A2) and (A3) of diacetoxydibutoxysilane.
 3. The method as defined in claim 1, wherein (A1) has a viscosity of between about 2,000 and about 200,000 cps at 25° C.
 4. The method as defined in claim 1, wherein (A1) has a viscosity of between about 3,000 and about 150,000 cps at 25 ° C.
 5. The method as defined in claim 1, wherein (A2) is present in an amount of from about 3 to about 20 parts by weight based upon (A1).
 6. The method as defined in claim 1, wherein (A2) is present in an amount of from about 5 to about 15 parts by weight based upon (A1).
 7. The method as defined in claim 1, wherein the silica filler (A2) has an average surface area of about 200 m² /gm in an untreated state.
 8. The method as defined in claim 1, wherein (A2) is trimethyl silyl treated.
 9. The method as defined in claim 1, wherein (A3) is present in an amount up to about 60 parts by weight based upon (A1 ).
 10. The method as defined in claim 1, wherein (A3) is present in an amount of up to about 30 parts by weight based upon (A1).
 11. The method as defined in claim 1, wherein (A3) has an average particle size ranging from about 0.05 to about 5 microns.
 12. The method as defined in claim 1, wherein (B1) is present in an amount of from about 0.01 to about 0.4 parts by weight based upon 100 parts of the base composition (A).
 13. The method as defined in claim 1, wherein (B1) is present in an amount of from about 0.05 to about 0.30 parts by weight based upon 100 parts of the base composition (A).
 14. The method as defined in claim 1, wherein (B1) comprises at least one of (a) dibutyltindilaurate or (b) dibutyltindiacetate.
 15. The method as defined in claim 1, wherein (B2) is present in an amount ranging from about 2 to about 15 parts by weight based upon 100 parts of the sum of (A1), (A2) and (A3).
 16. The method as defined in claim 1, wherein (B2) comprises at least one of (a) methyltriacetoxy, silane or (b) ethyltriacetoxysilane.
 17. The method as defined in claim 1, wherein the ratio of (B2)(c) to (B2)(b) ranges from about 100:0 to about 0:100.
 18. The method as defined in claim 1, wherein (B2) is present in an amount ranging from about 2 to about 10 parts by weight based upon 100 parts of the sum of (A1), (A2) and (A3).
 19. The method as defined in claim 1, wherein (B2) is present in an amount of from about 3 to about 7 parts by weight based upon 100 parts of the sum of (A1), (A2) and (A3).
 20. The method as defined in claim 2, wherein (B3) is present in an amount of from about 0.2 to about 2 parts by weight based upon 100 parts of the sum of (A1), (A2) and (A3).
 21. The method as defined in claim 2, wherein (B3) is present in an amount of from about 0.3 to about 1.5 parts by weight based upon 100 parts of the sum of (A1), (A2) and (A3).
 22. The method as defined in claim 1, wherein said base polymer (A) is processed at a temperature ranging from about 75° to about 150° C.
 23. The method as defined in claim 1, wherein said base polymer is processed at a temperature ranging from about 100° to about 150 ° C.
 24. The method as defined in claim 1, wherein said base polymer (A) is processed for up to about 5 minutes before adding the catalyst solution (B). 